Field of the Invention
[0001] The present invention relates to popcorn products and microwave product packaging.
In particular, the invention relates to packages for popcorn products that include
an outer package, a popcorn composition within the outer package, and an internal
containment package positioned within the external package, the internal containment
package configured to retain at least a portion of the popcorn composition.
Background
[0002] Microwave popcorn popping packages, such as flexible bags, are common. A common feature
of such bags is that they are generally made from paper materials that are sufficiently
flexible to open or expand conveniently under steam pressure, which forms when a popcorn
charge therein is exposed to microwave energy in a microwave oven. Also, the packaging
materials are sufficiently flexible to be formed from a sheet into a folded configuration,
for example during a continuous bag-construction process. Popcorn popping bags of
this type are described, for example, in U.S. Patent Nos. 5,044,777; 5,081,330; 5,195,829;
6,049,072; and 6,396,036. Popcorn popping bags are also described in U.S. Patent Nos.
4,904,488; 4,973,810; and 4,982,064.
[0003] U.S. Patent No. 4,596,713 provides a microwave popcorn package having an internal
containment pouch having an oil/fat component therein, with the internal containment
pouch constructed to burst upon an increase in pressure and release the oil/fat component.
[0004] DE-A-2739961 provides a transparent bag which contains an inner bag filled with flavorings
or other taste improving materials. Shortly before consumption, the flavorings or
taste improving materials can be released from the inner bag into contact with the
contents of the larger transparent bag.
[0005] Many microwave popcorn products include a charge of unpopped popcorn kernels, fat/oil
(i.e., grease) and flavoring (for example, salt) within the package. During storage
or shipment, especially if the environment becomes relatively hot, the material stored
within the bag can liquify and leak through the bag construction. To inhibit such
leakage, solid fat/oil products having a relatively high melting or softening temperature
(typically at least about 90-115°F) are used. Additionally or alternatively, some
bags are made from expensive materials, such as two ply papers, glassine paper, or
papers having a greaseproof coating thereon.
[0006] Improvements in microwave popcorn packaging are desired.
Summary of the Invention
[0007] In a first aspect of the present invention as defined in the appended claims, this
is provided a microwave popcorn product comprising microwaveable container, unpopped
popcorn kernels, an internal containment package positioned within the microwaveable
container, the internal containment package having a first cell and a second cell,
the first cell positioned within the second cell, water contained within the first
cell, an oil/fat component contained within the second cell, the internal containment
package constructed and arranged, due to the increase of pressure therein during a
microwave heating process, to burst and release the oil/fat component contained within.
[0008] The invention may further provide that at least a portion of the popcorn composition
is contained within an internal containment package positioned within the outer package.
The internal containment package is particularly suited for containing and retaining
any liquid or non-solid portion of the popcorn composition therein, that is, any liquid
or non-solid components or ingredients. Contained within the internal containment
package could also or alternatively be solid components or ingredients.
[0009] The internal containment package has an internal volume to contain at least a portion
of the popcorn composition. The containment package is constructed to release the
portion of the popcorn composition contained therein during the microwave heating
process. Alternatively, the containment package is constructed to be manually ruptured
or burst prior to the microwave heating process. The containment package is constructed
to retain liquid or semi-liquid components therein, reducing the need for the outer
package to use grease-proof paper or other liquid-proof materials, and, additionally
or alternatively, reducing the need for a package overwrap as a moisture barrier.
[0010] A preferred popcorn product includes at least a portion of the oil/fat component
of the popcorn composition contained within the internal containment package. By containing
the oil/fat component within the containment package, liquid or non-solid oils and/or
fats can be used in the popcorn product.
[0011] In another aspect of the invention, a low-trans fat microwave popcorn product, typically
having a liquid oil/fat component is provided, the liquid oil/fat component being
contained and retained within the internal containment package, which is positioned
in an outer package.
[0012] Another preferred microwave popcorn product, according to the present application,
provides a flexible microwaveable bag configured for expansion and an edible composition
within the bag. The edible composition comprises unpopped popcorn kernels and an oil/fat
component. The oil/fat component can include a liquid or non-solid composition. An
internal containment package is positioned within the expandable bag, with at least
a portion of the edible composition contained within a containment package; the internal
containment package is constructed and arranged, due to the increase of pressure therein
during a microwave heating process, to burst and release the portion of the edible
composition contained therein.
[0013] Still another preferred microwave popcorn product, according to the present application,
comprises a package having a microwave interactive susceptor; and an edible charge
having a low trans-fat level, the charge comprising unpopped popcorn kernels and an
oil/fat component.
[0014] Yet another preferred microwave popcorn product comprises a rigid microwaveable tub
and an edible composition within the tub. The edible composition comprises unpopped
popcorn kernels and an oil/fat component, which, at room temperature, has a liquid
portion. Positioned within the tub is an internal containment package with at least
a portion of the oil/fat component contained within the containment package, the internal
containment package constructed and arranged, due to the increase of pressure therein
during a microwave heating process, to burst and release the popcorn composition contained
therein.
[0015] Methods of popping a microwave popcorn product are also disclosed as defined in the
appended claims, one preferred method comprising exposing a popcorn product to microwave
energy, the popcorn product including an expansion source, increasing the expansion
source in volume by exposure to microwave energy and bursting a containment package
to release an oil/fat component and the expansion source present within the containment
package, and popping the popcorn. The popcorn product includes an expandable package
and an internal containment package within the expandable package. The internal containment
package is constructed and arranged, due to the increase of pressure therein during
a microwave heating process, to burst and release its contents.
Brief Description of the Drawings
[0016]
Figure 1 is a schematic top view of a microwaveable popcorn product, the product having
a composition including unpopped popcorn kernels within a package and a containment
package within the package which containment package can be provided according to
the present invention;
Figure 1A is a schematic cross-sectional view of a first embodiment of the containment
package of Figure 1, taken along line 5-5 of Figure 1 which can be provided with a
first and second cell structure according to the present invention;
Figure 1B is a schematic cross-sectional view of a second embodiment of the containment
package of Figure 1, taken along line 5-5 of Figure 1 which can be provided with a
first and second cell structure according to the present invention;
Figure 2 is a schematic top view of an embodiment of the containment package of Figure
1 which is useful as background to the invention;
Figure 3 is a schematic top view of an embodiment of the containment package of Figure
1 which is useful as background to the invention;
Figure 4 is a schematic top view an embodiment of the containment package of Figure
1 which is useful as background to the invention;
Figure 5 is schematic cross-sectional view of an embodiment of the containment package
of Figure 1, taken along line 5-5 of Figure 1 which is useful as background to the
invention;
Figure 6 is a schematic top view of an embodiment of the containment package of Figure
1 provided according to the present invention;
Figure 7 is a schematic top view of an embodiment of the containment package of Figure
1 which is useful as background to the invention;
Figure 8 is a schematic top view of an embodiment of the containment package of Figure
1 which is useful as background to the invention;
Figure 9 is a schematic top view of an embodiment of the containment package of Figure
1 which is useful as background to the invention;
Figure 10 is a front perspective view of a package being depicted closed in a storage
overwrap and oriented standing on an edge which can be provided with a containment
package according to the invention;
Figure 11 is a schematic top plan view of the package of Figure 10 showing a positioning
of a containment package according to the present disclosure, depicted unwrapped and
unfolded, as it would be when positioned in a microwave oven for cooking;
Figure 12 is a cross-sectional view taken generally along line 12-12 of Figure 11;
Figure 13A is a schematic, plan view of a package blank showing an adhesive pattern
on a first side of the blank, the adhesive used to generate a package of the arrangement
of Figures 10-12;
Figure 13B is a schematic, plan view of the package blank showing an adhesive pattern
between two plies of material, the adhesive used to laminate the two plies together
for the arrangement of Figures 10-12; and
Figure 14 is a schematic cross-sectional view of a fibreboard tub including a containment
package which can be provided according to the present invention.
Detailed Description of the Invention
[0017] As indicated above, the present disclosure concerns a popcorn product that includes
an outer package and a popcorn composition within the package, the composition including
unpopped, popcorn kernels, an oil/fat component, and optional flavoring. The present
disclosure provides an internal containment package, positioned within the outer package,
in which is contained at least a portion of the popcorn composition. The present invention
relates to a particular one of these internal containment designs.
[0018] Referring now to the Figures, a first package configuration is provided. Figure 1
schematically illustrates a popcorn product 10 that includes an outer package 12 having
an interior 15. Within interior 15 is the popcorn composition, which includes but
is not limited to unpopped popcorn kernels 18 and an oil/fat component 19. Popcorn
product 10 includes an internal containment package 20 within outer package 12; at
least a portion of the popcorn composition is present within internal containment
package 20. Preferably and typically, at least any ingredients of the popcorn composition
that are liquid or semi-liquid at typical room temperature are contained within containment
package 20, Solid ingredients may or may not be contained within containment package
20. In Figure 1, oil/fat component 19 is illustrated within package 20.
The Internal Containment Package
[0019] Internal containment package 20 is a package for retaining and containing ingredients
or components of the popcorn composition prior to a microwave heating process. Specifically,
package 20 is a pouch, vial, container, or other such package that has an internal
volume. Package 20, particularly internal volume 15', is constructed to contain and
retain a portion of the popcorn composition therein. Preferably, package 10, particularly
volume 15', is constructed to contain and retain liquid, semi-liquid, or non-solid
ingredients or components. Internal containment package 20 is non-vented, that is,
prior to package 20 bursting, there is preferably little or no exchange of air or
moisture from package 20, other than on a microscopic or atomic level.
[0020] Internal containment package 20 at least inhibits leakage of fluids therethrough
or therefrom; that is, package 20 as a whole, including any side panels, side walls,
seals or seams, inhibits leakage. Preferably, package 20, as a whole, is impermeable
to liquid leaking therethrough or therefrom. By use of the term "impermeable to liquid
leakage", and variations thereof, what is intended is that over a normal product life
(generally, a 2 year period) no more than 10% of the total edible material retained
by package 20 leaves package 20, either by evaporation, leakage, seepage, etc.
[0021] Figure 1 illustrates a generic internal containment package 20. The containment package
20 of Figure 1 is illustrated with side edges 20a, 20b, 20c, and 20d. It should be
understood that an internal containment package 20, in accordance with the present
disclosure, is not required to have side edges as illustrated in Figure 1. Rather,
Figure 1 is a generic depiction illustrate internal containment package 20 within
interior 15 of outer package 12. Internal containment package 20 could have a square
area, circular, triangular, hexagonal, or any such area. Various constructions and
configurations of internal containment package 20 are described below, including the
form according to the present invention.
[0022] A first construction of containment package 20 is a flexible, generally flat pouch.
Figure 1A illustrates a cross-sectional view of a flexible, generally flat pouch,
which represents, which represents internal containment package 20 of Figure I taken
along line 5-5 of Figure 1. This containment package 20, specifically, internal containment
package 20', is formed from a first sidewall 11 and a second sidewall 13, which defines
interior volume 15' of containment package 20'. Sidewalls 11, 13 are sealed together
at edges 20a, 20b. This seal may be made by any suitable means, including heat-sealing,
ultrasonic sealing, and by the use of an adhesive. In a variation, package 20' can
have a fold present at one of edges 20a, 20b and can be sealed together at the other
one of edges 20a, 20b. At least one of edges 20a, 20b, 20c, 20d includes a region
that will burst or release during microwave heating, so that the contents within interior
volume 15' are released. This release or burst region is further described below.
[0023] Examples of suitable materials for sidewalls 11,13 of internal containment package
20 include polymeric film (e.g., polyethylene, polypropylene, cellophane, mylar, silicon-oxide
coated films, aluminium-oxide coated films, polyester, and nylon), metal foil, metallized
polymeric film, treated papers, and laminated products thereof. The material should
be such that leak-proof seals can be made between sidewalls 11,13. One preferred material
for sidewalls 11, 13 is 150 gauge OL film commercially available from DuPont Teijin
Films. These materials, and the resulting containment package 20', are fairly flexible.
Additional details regarding internal containment package 20', and methods of making
package 20', are provided below.
[0024] A second construction of containment package 20 is a fairly rigid container, having
a measurable length, width and thickness. Figure 1B illustrates a cross-sectional
side view of a rigid, generally three-dimensional containment package 20", which represents
internal containment package 20 of Figure 1, taken along line 5-5 of Figure 1. This
containment package 20, specifically, internal containment package 20", is formed
from a topwall 11', a base 13', a first edge wall 7 at edge 20a and a second edge
wall 9 at edge 20b, which together define internal volume 15' of containment package
10". Internal containment package 20" can be cylindrical, cubic, block-like, spherical
or senu-spherical, or have any other three dimensional shape. Internal containment
package 20" is typically made from less flexible, more rigid materials than the flexible,
polymeric materials disclosed above for containment package 20'. Examples of suitable
materials for containment package 20" include wax, cellulose, gelatin, and the like.
Preferably these materials are nontoxic and are foodgrade. Internal containment package
20" is particularly suitable as a manual-burst containment package.
[0025] Containment package 20 (whether containment package 20' or containment package 20")
is positioned inside package 12. Internal containment package 20 can be attached or
secured to an interior surface, such as a side panel or an end seam of package 12.
An adhesive can be used to secure package 20 to an interior surface. Additionally
or alternately, package 20 can be sealed or attached into an end or side seam of package
12 during manufacture of package 12. Alternately, package 20 can be unattached to
an interior surface of outer package 12. An internal package 20 that is initially
unattached or unsecured to interior 15 of outer package 12 could include a heat activated
adhesive thereon, so that during microwave heating, internal package 20 would adhere
to interior 15.
[0026] Containment package 20 is preferably positioned in close proximity to popcorn kernels
18, and preferably the entire containment package 20 is within interior 15, although
in some designs a portion of containment package 20 may be present on the exterior
of package 15.
[0027] As stated above, containment package 20 can contain and retain any or all of unpopped
popcorn kernels 18, oil/fat component 19, flavors, additives, and any other component
of the popcorn composition.
Popcorn Kernels
[0028] Unpopped popcorn kernels 18 are any hulled or dehulled popcorn kernel known for use
in microwave popcorn products. The kernels may be large, medium, small, white, yellow,
flavored, or any type of available kernel. Usually, the popcorn kernels have an internal
moisture level of about 11-16%.
Oil/Fat Component
[0029] Oil/fat component 19 facilitates the even distribution of heat to popcorn kernels
18 prior to and during popping of kernels 18. Oil/fat component 19 further facilitates
the distribution of flavor among popcorn kernels 18 by splashing, pouring, spraying,
blowing or otherwise distributing itself and any flavor over the popped popcorn flakes.
Oil/fat component 19, when present in the popcorn composition, is generally a separable
component from kernels 18. That is, oil/fat component 19 is not appreciably absorbed
by or present within the interior of kernels 18.
[0030] Oil/fat component 19 refers to materials that are primarily tri-fatty acid esters
of glycerol. Fat is a natural lipid material that is mainly solid at room temperature.
Oil is similar to fat, but is liquid at room temperature. The term "oil/fat component"
is meant to refer to oil(s), fat(s) (natural or modified) and any mixtures thereof.
The "oil/fat component" may be a solid, liquid, or semi-solid at room temperature.
Many forms of oil/fat component 19 are substantially solid at room temperature prior
to the popping process, and readily melt during the microwave popcorn popping process.
When the terms "liquid", "semi-solid", "non-solid" and other such terms are used,
what is intended is an oil/fat component which, at room temperature, is flowable and
does not hold a third dimensional shape if not retained by a mold or other structure
for one hour. That is, a liquid, semi-solid or non-solid oil/fat component 19 will
slump or otherwise loose a formed shape within one hour.
[0031] Preferred oils for use in oil/fat component 19 include non-hydrogenated and/or partially
hydrogenated vegetable oils. Suitable oils include those obtained from sunflower oil,
safflower oil, rapeseed oil, cottonseed oil, maize oil, linseed oil, groundnut oil,
and soybean oil. Other suitable oils include nut oils (such as almond, brazil nut,
cashew, coconut, hazelnut, pecan, peanut, and walnut), olive oil, palm oil, sesame
oil, and flaxseed oil. Non-fat oils, such as olestra (e.g., commercially available
under the trade name Olean) are also suitable for use.
[0032] The amount of oil/fat 19 within popcorn product 10, in relation to the unpopped popcorn
kernels, is no more than about 50 wt-%, and is typically no more than about 40 wt-%.
The amount of oil/fat 19 is usually at least 1 wt-% and typically at least 5 wt-%.
Flavorants
[0033] Popcorn product 10 of the present invention can include any suitable type of flavorant
or flavoring, depending on the specific characteristics and/or flavor the final product
is to have. In typical applications, product 10 will include various flavorants, colorants
and other adjuvants in the popcorn composition. Typical components that might be included
in the popcorn composition are salt and butter flavor. Other suitable flavors include
sweet, sour, sugary, savory, tart, spicy, fruity or any other flavor. Examples of
specific flavors include, but are not limited to: butter, cheese(s), sour cream &
chive, dill, herb, onion, garlic, jalapeno, bacon, pizza, tomato, salt & vinegar,
barbecue, taco, cinnamon, nutmeg, hickory and smoke. The flavorants may be present
as a liquid or a solid, and may be contained within a cell of internal containment
package 20 or be external to internal containment package 20 within interior 15 of
outer package 12. It should be understood that the amount of flavorant present in
the popcorn composition prior to popping and in the popped product will largely depend
on the specific flavorant used.
Expansion Source
[0034] In one design of containment package 20, in order to release the ingredients or components
contained within package 20, containment package 20 includes an expansion source therein
that bursts or opens package 20. This expansion source is generally a moisture source
such as liquid water, although moisture present in other ingredients, such as the
unpopped popcorn 18, is also suitable. An amount of moisture or other expansion source
is desired within containment package 20 in order to burst or otherwise penetrate
containment package 20. Most oil/fat compositions do not appreciably expand in volume
during microwave heating, however, emulsions or other oil/fat components that include
water therein, such as a margarine emulsion, will release water upon heating, allowing
steam to expand and burst containment. Water expands at least about 1200 times the
volume (at the same pressure) as it heats from room temperature (about 20°C) to its
boiling temperature (100°C).
[0035] The moisture source present within internal containment package 20 sufficiently expands
to burst package 20 usually within about 15-45 seconds after the initiation of microwave
energy from a conventional residential microwave oven, usually 800-1200 watts. It
is preferred that internal containment package 20 bursts prior to popcorn 18 popping.
[0036] Referring to Figures 2 through 9, various embodiments of containment package 20 are
illustrated. Figures 2 through 6 illustrate multiple cell or multiple chamber containment
packages and Figures 7 through 9 illustrate single cell or chamber containment packages.
The embodiments illustrated in Figures 2 through 9 are generally flexible, fairly
flat packages, made from polymeric film; these embodiments are similar to containment
package 20' in Figure 1A.
Multiple Cell: (background of the invention)
[0037] Containment package 20 of Figure 2 is specifically containment package 21 having
a first cell 21a and a second cell 21b. First cell 21 a retains an expansion source,
water 17, and optionally but preferably salt, and second cell 21 b retains oil/fat
19.
[0038] Containment package 20 of Figure 3 is specifically containment package 22 having
a first cell 22a and a second cell 22b. Similar to containment package 21 of Figure
2, first cell 22a of Figure 3 retains a volume of water 17, and optionally but preferably
salt, and second cell 22b retains oil/fat 19.
[0039] Packages 21, 22 differ in that containment package 21 of Figure 2 is constructed
so that each of first cell 21a and second cell 21b individually bursts/through a side
edge of package 21. First cell 21a has a first burst region 31a and second cell 21b
has a second burst region 31b. Each of burst regions 31a, 31b extends from cells 21a,
21b, respectively, and, when burst or otherwise ruptured, provides a passage from
cell 21a, 21b to the exterior of containment package 21 through side edge 20c. In
the embodiment of Figure 2, increased pressure within cell 21a will burst both regions
31a and 31b.
[0040] Burst regions 31a, 31b, and all others described herein, are regions within containment
package 20 that are a weakness or other structure of package 20 designed to burst
upon the build-up of pressure within the cell and release the pressure from the interior
15'. The burst region may be a weaker seal at a side edge, such as at edge 20c, a
perforated area, a slit, a notch, or other such structure that weakens the structure
and creates a weak point.
[0041] In package 22 illustrated in Figure 3, first cell 22a has a first burst region 32a
and second cell 22b has a second burst region 32b. Unlike the configuration of package
21 of Figure 2, burst region 32a is designed so that the contents of first cell 22a,
water 17, bursts into second cell 22b. The mix of water 17 and oil/fat 19 then bursts
from second cell 22b via region 32b through side edge 20a. The rupturing of first
burst region 32a and second burst region 32b may be simultaneous or sequential.
[0042] As discussed above, containment package 21 of Figure 2 and containment package 22
of Figure 3 include expansion source water 17, and optionally but preferably salt,
in first cell 21a, 22a and oil/fat 19 in second cell 21b, 22b. Popcorn product 10,
such as that illustrated in Figure 1, that incorporates either of package 21 or package
22 would include a charge of popcorn 18 in volume 15 external to package 21, 22. Thus,
during the microwave heating of a popcorn product having either package 21 or package
22, containment package 21, 22 would burst, providing oil/fat 19 to cover popcorn
18 and facilitate its popping. Water 17 is typically released as steam from containment
package 21, 22, although some liquid water 17 may be splashed onto popcorn 18.
[0043] Another embodiment of a multiple cell containment package 20 is illustrated in Figure
4. Specifically, Figure 4 shows a containment package 23 having a first cell 23a and
a second cell 23b. Containment package 23 has a first burst region 33a extending from
first cell 23a to second cell 23b, and a second burst region 33b extending from second
cell 23b to side wall 20a.
[0044] Similar to containment package 22 of Figure 3, first cell 23a of Figure 4 retains
water 17, and optionally but preferably salt, therein, and second cell 23b retains
oil/fat 19 therein. Second cell 23b additional includes a charge of popcorn 18 therein.
In alternate constructions, popcorn 18, with or without some amount of oil/fat 19,
may instead be present in first cell 23a, with additional oil/fat 19 in second cell
23b. In such a construction, the moisture within popcorn 18 provides the moisture
needed to rupture first cell 23a. Additional popcorn 18 may or may not be present
within interior 15 of package 12.
[0045] Figure 5 illustrates a variation of multiple cell containment packages 21, 22 and
23 described above. Figure 5 illustrates a multiple cell containment package often
referred to as a "sandwich" containment package. That is, rather than the first cell
and the second cell being positioned next to each other, as in packages 21, 22 and
23, in the embodiments of Figure 5, the first cell and second cell are stacked. Additional
details are found below and in conjunction with Figure 5.
[0046] Specifically, containment package 20 of Figure 5 is a containment package 24 having
a first cell 24a and a second cell 24b. First cell 24a contains water 17, and optionally
and preferably salt, and second cell 24b contains oil/fat 19.
[0047] First cell 24a and second cell 24b are defined by cell walls 41, 43 and 45; specifically,
first cell 24a is defined by walls 41 and 45 and second cell 24b is defined by walls
43 and 45. Walls 41, 43, 45 meet and are sealed at edges 20a and 20b. Containment
package 24 has a first burst region 34a extending from first cell 24a and a second
burst region 34b extending from second cell 24b. Each burst region 34a, 34b, located
at edge 20b, is designed to burst or release between the respective cell walls. That
is, first burst region 34a will burst the seal between walls 41 and 45, and second
burst region 34b will burst the seal between walls 43 and 45. Burst regions 34a, 34b
are similar to burst regions 31 a, 31b, in that the regions are structured so that
the build-up of pressure within cell 24a will burst both regions 34a and 34b.
Multiple cell: present invention
[0048] In Figure 6, a variation of a multiple cell containment package 20 according to the
present invention is illustrated, specifically internal containment package 25 having
a first cell 25a within a second cell 25b. First cell 25a may be free-floating or
unsecured within second cell 25b, or a first cell 25a maybe fixed or secured within
second cell 25b. A secured first cell 25a can share a side wall with second cell 25b.
First cell 25a, positioned within second cell 25b contains water 17 and optionally
and preferably salt, and second cell 25b contains oil/fat 19. First cell 25a has first
burst region 35a, and second cell 25b has second burst region 35b. Build up of pressure
within first cell 25a will cause burst region 35a to release, thus increasing pressure
in second cell 25b and thus causing burst region 35b to break. Second burst region
35b may rupture simultaneously with or subsequent to first burst region 35a.
Single Cell (background to the invention)
[0049] Referring now to Figures 7 through 9, containment packages 20 having a single cell
or chamber are illustrated. Specifically, Figure 7 shows containment package 26, Figure
8 shows containment package 27, and Figure 9 shows containment package 28. Similar
to containment packages 21, 22, 23, 24 and 25, described above, containment packages
26, 27 and 28 of Figures 7-9 retain oil/fat 19 and a moisture source, except, however,
containment packages 26, 27 and 28 of Figures 7-9 have a single cell for retaining
both the oil/fat and the moisture source.
[0050] Containment package 26 of Figure 7 has cell 26a which retains water 17 and optionally
but preferably salt, and oil/fat 19 therein. A burst region 36 extends from cell 26a
to side edge 20c. Water 17 may be intimately mixed with oil/fat 19, for example, as
an emulsion. In most constructions, water 17 and oil/fat 19 are non-miscible, and
an emulsion is preferred.
[0051] In a variation of containment package 26, oil/fat 19 can be present within cell 26a
with no water 17 present therein. With no expansion source present, cell 26a will
typically not rupture without intervention, which can be provided by the consumer.
That is, immediately prior to placing the popcorn package in the microwave oven, the
consumer can manually rupture the containment package 26, for example by hand pressure,
to release oil/fat 19. It is understood that any containment package 20 can be manually
ruptured if desired.
[0052] Containment package 27 of Figure 8 is similar to the illustrated containment package
26 of Figure 7 in that it has a cell 27a and a burst region 37 extending from cell
27a to side edge 20c, except that package 27 of Figure 8 retains a modified oil/fat
product 19', such as an emulsion, which incorporates in it a moisture source. There
is no liquid water within cell 27a.
[0053] Likewise, containment package 28 of Figure 9 is similar to package 26 of Figure 8
by having a cell 28a and a burst region 38 extended from cell 28a to side edge 20c.
Containment package 28 includes no liquid water within cell 28a; instead, cell 28a
retains oil/fat 19 and a charge of popcorn kernels 18. Popcorn 18 within cell 28a
provides sufficient moisture to have cell 28a expand and burst.
[0054] The various containment packages 20 illustrated and described above provide a secure
location for ingredients that are usually liquid or otherwise flowable at usual room
temperatures, so that the liquid does not leak or otherwise cause a mess. Ingredients
that are usually liquid at room temperatures include fats and oils. Although only
water 17, popcorn 18 and oil/fat 19, have been described as being present within containment
package 20, flavorants or other adjuvants could also be retained and contained within
package 20, particularly any liquid flavorants or other adjuvants.
Expansion Source Revisited
[0055] As described above, it is desired to have an expansion source present to facilitate
opening or bursting of containment package 20 to release fat/oil 19 retained inside.
Typically, this expansion source is a moisture source, such as liquid water.
[0056] The amount of moisture is such so that the volume increase in the moisture caused
by microwave heating is sufficient to burst or otherwise break the seal or the burst
region on the cell in which water 17 or other moisture source is contained. It is
understood that the specific amount of moisture will depend on the size of the cell,
the presence of other elements within the cell, elements such as oil/fat 19, popcorn
18, flavorants, and even air. For preferred popcorn products having about 99 grams
of edible components, about 1-2 grams of saline water (having 6.25% wt-NaCl) as expansion
source are used.
[0057] For a multiple cell containment package 20, where oil/fat 19 and water 17 are contained
separately, the amount of water 17, as a ratio to oil/fat 19, is at least 1:250. The
amount of water 17, as a ratio to oil/fat 19 is no greater than 1:5, and often no
greater than 1:6.25. Typically the ratio of water 17 to oil/fat 19 is 1:50 to 1:15.
A ratio of 1:16.7 water:oil/fat is one preferred ratio.
[0058] For a single cell containment package 20, where the oil/fat 19 and water 17 are present
in the same cell, the ratio of water 17 to oil/fat 19 is at least 1:250. The amount
of water 17, as a ratio to oil/fat 19 is no greater than 1:5, and often no greater
than 1:6.25. Typically the ratio of water 17 to oil/fat 19 is 1:50 to 1:15. A ratio
of 1:16.7 water:oil/fat is one preferred ratio.
[0059] For embodiments having a modified oil/fat 19' such as an emulsion of water in oil/fat,
the amount of water 17 in oil/fat 19' is at least 0.05% by weight; the amount of water
in oil/fat 19' is generally no greater than 25% by weight. In some embodiments, it
is possible to use a "reversed-emulsion", having oil/fat dispersed within an aqueous
solution, and thus having more than 25% by weight water content.
[0060] In the "manual burst" package 20 described above, an embodiment of which is illustrated
in Figure 1B as internal containment package 20", no moisture would be necessary to
release oil/fat 19, as package 20 is ruptured manually by the consumer or by other
physical means. If the manual burst package 20 is generally flexible application of
pressure for example rolling the palm of the hand is usually sufficient to burst package
20. A rigid manual burst package 20 could be manually snapped or cracked.
[0061] The unpopped popcorn kernels 18 are also a good source of moisture. Popcorn kernels
18 usually have a moisture content of about 11-16%; depending on the amount of popcorn
18 and the size of the cell, the expansion of this moisture is generally sufficient
to burst the seal on the cell.
[0062] Vaporization of the water, and thus steam, can be generated more quickly by the addition
of salt to the water. By use of the term "salt", what is intended is edible anionic
salts of chloride and iodide, most commonly sodium chloride. It is preferred to have
some salt present in water 17. If present, the amount of salt added to the water is
typically at least 0.5 part per 100 parts water, to make about a 0.5% saline solution.
Typically, the amount of salt added to the water is no greater than about 15 parts
salt per 100 parts water (about a 13% saline solution) and more typically, the amount
of salt added to the water is not greater than about 10 parts per 100 parts water
(about a 9% saline solution). A suitable and common range of salt:water includes 1:100
to 5:100 (about 1% saline to about 5% saline). The salt added to the water will provide
some degree of flavoring to the popped popcorn. However in most cases, additional
salt will be present in other locations within product 10, such as with fat/oil 19
or with popcorn kernels 18.
[0063] The salt used is typically sodium chloride (common table salt or sea salt), although
other salts such as potassium chloride, potassium iodide, sodium iodide, calcium chloride,
may be suitable. Any size of salt may be used. Common sizes of salt include those
known as table salt or flour salt.
[0064] The following table provides a definition of preferred popcorn compositions, prior
to being popped, based on the entire edible product.
Ingredient |
Typical |
Preferred |
Most Preferred |
One Example |
|
wt-% |
wt-% |
wt-% |
grams |
Unpopped popcorn kernels |
≥50 wt-% |
60-85 wt-% |
64-70 wt-% |
69.5 grams |
Oil/Fat |
≤ 50 wt-% |
≤30 wt-% |
24 - 30 wt-% |
27.05 grams |
Saline solution (6.25 wt-% NaCl*) |
0.1 - 10 wt-% |
0.5 - 5 wt-% |
1 - 2 wt% |
1 gram |
Other Flavorants |
< 5 wt-% |
≤3 wt-% |
|
2.75 grams |
* The 6.25 wt-% saline solution was made by combining 15 grams water with 1 gram NaCl. |
No or Low Trans-Fat Popcorn Product
[0065] As stated, containment package 20 provides a suitable and convenient package for
retaining and containing any and all liquid ingredients or components of the popcorn
composition. Many oil/fats 19, particularly those having no-trans fat or low-levels
of trans fat, are liquid at room temperature. Trans-fat is also commonly referred
to as "trans-fatty acids" or variations thereof. Examples of oils and/or fats that
can be considered to be trans-fat free or low-trans fat include sunflower oil, canola
oil, corn oil, olive oil, soy oil, peanut oil, palm oil, and coconut oil.
[0066] Because typical trans-fat free oils/fats are liquid or non-solid at room temperature,
the trans-fat free oils/fats are preferably retained within containment package 20
as oil/fat 19 or as oil/fat 19'. The popcorn product of the present invention could
include a source of oil/fat that is not contained within containment package 20, but
is present within interior 15 of package 12. Typically, any oil/fat present outside
of containment package 20 is solid or semi-solid at room temperature.
[0067] For this application, a popcorn product having "no trans-fat" or being "trans-fat
free" has no more than 5 grams of trans-fat per 100 grams of edible product. A product
having "low trans-fat" has no more than 10 grams of trans-fat per 100 grams of edible
product.
[0068] In a preferred product configuration, the entire edible component, including oil/fat
19 within package 20 and any other oil/fat, includes no more than 5 wt-% of trans-fat,
preferably no more than 1.5 wt-% of trans-fat. Any trans-fat may be present within
containment package 20, either in the same cell as the no trans-fat or low trans-fat
or in a separate cell, or, a trans-fat may be present outside of package 20. It may
be desirable to add an amount of trans-fat, such as partially hydrogenated soybean
oil, to the popcorn product, for example, to modify the taste of the popped product,
to contain additional salt and/or flavors, or to retain a product load on the susceptor.
It is preferred, however, that the amount of trans-fat is no more than about 10 wt-%
of the entire oil/fat component, preferably no more than about 5 wt-%.
[0069] The following table provides a definition of preferred no trans-fat or low trans-fat
popcorn compositions, prior to being popped, based on the entire edible product.
Ingredient |
Typical |
Preferred |
Most Preferred |
One Example |
|
wt-% |
wt-% |
wt-% |
grams |
Unpopped popcorn kernels |
≥50 wt-% |
60 - 85 wt-% |
64 - 70 |
69.5 grams |
Trans-fat Free Oil/Fat |
<50 wt% |
≤30 wt-% |
24-30 wt-% |
24.8 grams |
Trans Oil/Fat |
≤5 wt-% |
≤2 wt-% |
≤1.5 wt-%, even more pref. ≤1 wt-% |
1.5 grams |
Saline solution (6.25 wt-% NaCl*) |
0.1 - 10 wt-% |
0.5 - 5 wt-% |
2 - 5 wt% |
1 gram |
Other Flavorants |
≤5 wt-% |
≤3 wt-% |
|
2.75 grams |
* The 6.25 wt-% saline solution was made by combining 15 grams water with 1 gram NaCl. |
The Containment Package, Revisited
[0070] Returning to containment package 20, as described above, package 20 is a mechanism
for providing a retainer, receptacle, or other container to retain liquid components,
such as oil/fat 19, including no or low trans-fat substance oil/fat 19, so that under
typical storage and usage conditions of popcorn product 10, these liquid components
do not leak from product 10.
[0071] Typically, containment package 20 is a fairly two dimensional or flat pouch, made
from a material that inhibits water 17, oil/fat 19, and any other ingredients or components
from seeping therethrough, preferably, eliminates seeping therethrough. Examples of
suitable materials for package 20 include polymeric film (e.g., polyethylene, polypropylene,
mylar, silicon oxide coated films, aluminum-oxide coated films, other metallized films,
polyester, nylon, or other poly resin materials), metal foil, treated papers, and
laminated products thereof. The material should be such that leak-proof seals can
be made between plies of the material. Examples of suitable sealing methods include
adhesives, heat sealing (e.g., sealing under heat and pressure), or ultrasonic sealing.
[0072] Containment package 20 can be made by any number of methods. One preferred method
for making package 20 is to overlap two sheets of material, such as polymeric material,
heat seal three sides (e.g., side edges 20a, 20b, 20d of Figure 1) and any internal
seals between cells, fill the cell(s), and seal the last side (e.g., side edge 20c).
Another preferred method is to fold a sheet of polymeric material, the fold forming
a first side, such as side edge 20d, heat sealing side edges 20a, 20b and any internal
seals, filling the cell(s), and sealing side edge 20c. Yet another method is to use
a tube of material (the tube forming side edges 20a, 20b), sealing side edge 20d and
any internal seals, filling the cell(s), and sealing side edge 20c.
[0073] The overall size of containment package 20 should be such that adequately retains
the cell(s) and provides an adequate seal around the cell(s). For example, for some
packages 20, a heat seal 5/8 inch thick (about 1.6 cm thick) is provided on all sides
of package 20.
[0074] The size of the containment package 20 cells should be adequate to contain the amount
of oil/fat 19, water 17, popcorn 18, and any other ingredients that might be retained
within package 20. For a dual cell package, such as packages 21, 22, 23 of Figures
2, 3 and 4, each cell typically has a volume of at least 2 cm
3, prior to expansion. The specific volume of the cell depends on its contents. For
example, if 22 grams of oil/fat 19 are retained in a cell, the cell volume is preferably
about 25 to 60 cm
3. For 1.5 grams of water or saline 17, the cell volume is preferably about 2 to 20
cm
3. If popcorn 18 is present within the cell, the cell should be sufficiently large
to retain all of the popcorn 18, oil/fat 19, and other ingredients.
[0075] Containment package 20 preferably includes burst region 31a, 31b, 32a, 32b, etc.,
as described above. These burst regions may be a weakness in the seal between or around
the cells, or may be a notch, slit, perforation, or other weakness formed within the
seal. The function of the burst region is to direct where package 20 will burst. It
should be understood that the burst region could be positioned in any side edge of
package 20. An example of a suitable burst region is a triangular notch cut into the
seal. A slit in the seal is also suitable as a burst region. Usually, the distance
that the burst region extends into the seal is no more than 90% of the width of the
seal, typically no more than about 75%. Preferably, at least 0.25 inch of the seal
is left without a burst region. The burst region depth or length could be a low as
0.062 inch.
[0076] A popcorn composition and containment package 20, with at least a portion of the
popcorn composition retained within package 20, is positioned within a package. In
the embodiment illustrated in Figure 1, unpopped popcorn kernels 18 are present in
interior 15 outside of package 20 and oil/fat is present within containment package
20. Package 12 can be any type of suitable microwave popcorn package such as an expandable
bag or a tub. Containment package 20 is positioned within interior 15 of package 12,
positioned to minimize interference with expansion of package 12 during microwave
heating. Preferably, package 20 is attached or secured to package 12 rather than freely
positioned within interior 15. By use of the terms "attached", "secured", or the like,
what is intended is that at least a portion of the internal containment package 20
is fixed to and immovable in respect to interior 15 of outer package 12. The terms
"unattached", "unsecured", freely positioned" and the like, are intended to mean that
the internal containment package is movable in respect to interior 15 of outer package
12.
[0077] Additionally, containment package 20 is preferably positioned, whether secured or
unsecured, in package 12 so that popcorn 18 is positioned in close proximity to any
microwave interactive susceptor in package 12. Depending on the specific construction
of package 20 and the components therein, typically, popcorn 18 is between the susceptor
and containment package 20, although in embodiments such as a single cell internal
containment package having popcorn kernels 18 therein, popcorn 18 may not be between
the susceptor and internal containment package 20, but will be within package 20,
as described above. It should be understood that internal containment package 20 could
be positioned anywhere in interior 15 of outer package 12.
[0078] Containment package 20 is typically attached to package 12 during the production
of package 12. Examples of specific, suitable packages 12 are described below.
Packages for Popcorn Products
[0079] As discussed above, the unpopped, microwaveable popcorn composition is provided in
package 12 to form popcorn product 10. In general, such a package can be an expandable,
flexible bag, such as in accord with U.S. Patent Nos. 5,044,777 (Watkins et al.),
5,690,853 (Jackson et al.), 5,650,084 (Bley) or. 6,049,072 (Olson et al.), or a rigid
tub, such as in accord with U.S. Patent Nos. 5,008,024 (Watkins) or 5,834,046 (Turpin
et al.). In typical preferred packages, the microwave package contains a microwave
interactive construction or susceptor, to enhance the popping operation. Such susceptors
are described for example in U.S. Patent Nos. 5,149,396 (Wilson); 5,175,031 (Ochocki);
5,338,911 (Brandenberg et al.); and 5,285,040 (Brandenberg et al.).
[0080] Attention is now directed to Figures 10-14. In Figure 10, a flexible microwave popcorn
bag 101 is depicted stored or oriented substantially vertically. Bag 101 is depicted
in a trifold configuration 102, included with an overwrap 103 for storage. In Figure
11, a top plan view of popcorn bag 101 is shown schematically in an unfolded configuration
and oriented much as it would be when positioned in a microwave oven for popping of
the popcorn charge contained therein, but before expansion of the package. The term
"flexible" is meant to refer to a bag and bag material which is not so stiff or rigid
as to undesirably interfere with bag expansion during use. Alternately stated, the
term is used to refer to a bag that can be readily folded and unfolded.
[0081] In Figure 11, lines 111 and 112 indicate fold lines which define central region 113
of the arrangement. Inside the bag in central region 113, unpopped popcorn 18 and
containment package 20 would generally be positioned in orientation above a portion
of the bag in which a microwave interactive construction (susceptor) is positioned.
The term "microwave interactive" is meant to refer to a material that becomes hot
upon exposure to microwave energy in a microwave oven. Typical microwave interactive
constructions comprise a metallized polymeric component (for example, aluminized products)
positioned in bag 101.
[0082] During the popping operation, any expansion source, such as water, absorbs microwave
energy and expands, thus bursting the cell(s) of containment package 20 and releasing
oil/fat 19. This moisture also generates sufficient steam and heat for popping and
for expansion of bag 101. In addition, the microwave interactive material also absorbs
microwave energy and dissipates heat to the popcorn composition.
[0083] Attention is now directed to Figure 12, a cross-section taken generally along line
12-12 of Figure 11. In Figure 12 it can be seen that bag 101 generally comprises a
double wall (or two-ply 146, 147) configuration defining first and second opposite
panels 120 and 121 joined by first and second side gussets 122 and 123. Gussets 122
and 123 generally separate popcorn bag 101 into first and second expandable tubes
128 and 129. Popcorn charge 118 is substantially positioned and substantially retained
within tube 128. Underneath popcorn charge 118, bag 101 includes a microwave interactive
construction or susceptor 145. In certain arrangements, such as the one shown in Figure
10, susceptor 145 is positioned between plies 146, 147 from which flexible bag 101
is folded. Containment package 20 is positioned within expandable tube 129, preferably
adhered to ply 147. Thus, the construction shown in Figure 12 has popcorn charge 118
positioned between susceptor 145 and containment package 20.
[0084] In Figure 13A, a panel 160 is shown; panel 160 is a blank or sheet of flexible material
from which bag 101 is folded. Panel 160 includes various sealant fields 161, 162,
163 thereon, shown in dot pattern, which provide desired features in the resulting
folded bag 101. Sealant fields 161, 162 provide a package, as is described in U.S.
Patent No. 5,650,084, having end gussets. Sealant field 163 is used to adhere a microwave
susceptor to panel 160. In one embodiment, this sealant field 163 is about 6.5 inches
by 5.625 inches.
[0085] Panel 160 is typically formed from two plies of paper laminated together, as illustrated
in Figure 12 with plies 146, 147. A preferred lamination adhesive pattern is illustrated
in Figure 13B on panel 160; it should be understood that the adhesive pattern illustrated
in Figure 13B is present between two plies, which are then used to form panel 160
described above having sealant fields 161, 162, 163. Various sealant fields are present
on panel 160 in Figure 13B, particularly, sealant fields 165, 167, 169. Sealant field
165 is present at the center of panel 160 and includes a field of continuous coverage
of adhesive. The microwave interactive susceptor is typically present within the area
of field 165. Sealant fields 167, which also are areas of continuous coverage of adhesive,
are present at the ends of panel 160. Sealant fields 169 include crossing lines of
adhesive, having portions of panel 160 uncoated with adhesive. Approximately 55% of
the surface of panel 160 is covered by adhesive.
[0086] An outside border 170, defined at least by sealant fields 167 and the area designated
by broken lines 172, is positioned at the perimeter of panel 160. Border 170, in preferred
arrangements, is about 0.625 to 1.125 inches wide. Outside border 170 comprises a
region completely covered by adhesive. In the embodiment illustrated in Figure 13B,
the portion of sealant fields 167 within border 170 forms a region completely covered
by adhesive. Additionally, the portion of sealant field 165 within border 170 forms
a region completely covered by adhesive. The portion of sealant field 169 within border
170 forms a region having a contiguous region of adhesive.
[0087] In alternate embodiments, popcorn product 10 can have a rigid tub configuration,
as for example shown schematically in Figure 14 and characterized in U.S. Patent No.
5,384,024. A cross-section of such a tub 200 is depicted in Figure 14, containing
popcorn charge 218, a microwave interactive susceptor 210, and internal containment
package 20. Popcorn charge 218 is positioned in proximity to susceptor 210 and between
susceptor 210 and containment package 20. Such tubs are generally made from a paperboard
or fiberboard material, with a flexible film used for a cover. In general, with such
arrangements, a cover 205 expands or balloons under the heat and steam produced during
the popcorn popping operation. Containment package 20, in this embodiment, is attached
to cover 205. Tub 200 has an inverted, rigid conical sidewall construction 215 that
facilitates nesting and stacking, facilitates popping of charge 218, and provides
a bowl after popping and opening/removal of cover 205.
[0088] The invention will be further described and illustrated in the examples that follow.
The examples are illustrative of the invention and should not be construed as limiting
the scope to their details. All parts, percentages, ratios, etc. are by weight unless
otherwise specified.
Example 1 (background of the invention)
[0089] Example 1 was a popcorn product incorporating a single cell containment pouch for
containment of trans-fat free oil. Multiple (approximately 30) containment pouches
were made and tested using the following materials and procedures. The materials used
for Example 1 were as follows:
pre-made microwave popcorn bags (such as those shown in Figs. 1-4 of U.S. Patent No.
6,049,072, except having the adhesive pattern illustrated in Figure 13A of this application
and the lamination adhesive pattern illustrated in Figure 13B)- unsealed at both ends;
150 gauge sealable "OL Mylar" film-10 inch (25.4 cm) wide rolls - commercially available
from DuPont Teijin;
"Duracet" heat activated glue;
margarine type emulsion containing water, salt, and one or both of corn oil, and NuSun
mid-oleic acid sunflower oil, the emulsion commercially available from various oil
suppliers;
partially hydrogenated / winterized soybean oil,
powdered salt, mesh size 200 (75 micrometer);
partially hydrogenated soybean oil; and
un-popped kernels of microwave popcorn.
[0090] Containment pouches were made by cutting the mylar film into rectangular pieces measuring
5.0 inches x 5.5 inches (12.7 cm x 14 cm). Two pieces of the film were stacked on
each other, with the sealant layer surfaces facing each other. The two width (shorter,
5.0 inch (12.7 cm)) sides and one of the length (longer, 5.5 inch (14 cm)) sides of
the pieces of film were sealed with the heat sealer (model 12-ASL heat sealer from
Sencorp Packages Inc). The seals were between about 0.5 inch (1.3 cm) and 0.625 inch
(1.6 cm) wide. The sealer was set for 0.6 seconds, 240 °F (115 °C), and with a seal
bar pressure of 80 PSI.
[0091] While holding the pouch open, 22.8 grams of the margarine-type emulsion were placed
into the pouch; care was taken to not contaminate the fourth, future seal area with
the emulsion. Next, the fourth seal on the pouch was made using the same technique
as the other three seals. With a scissors, a 0.25 inch (0.64 cm) slit was made in
the center of the last (length side) seal. A thin coating of Duracet heat activated
glue was applied to both sides of the non-slitted length seal.
[0092] After the Duracet glue was dry, the containment pouch was inserted into the bottom
end of the pre-made bag so that the long (5.5 inch (14 cm)) side of the pouch was
parallel with the end of the bag. The side of the pouch with the slit was positioned
towards the center of the bag, and the side with the Duracet was positioned near the
bottom seal area of the bag. The containment pouch was positioned between the top
layer of the bag (the side without the susceptor) and the gussets, with the edge of
the pouch centered in the bottom seal area of the bag. The bag end was sealed with
the heat sealer, thus sealing the containment pouch in its position. The sealer was
set for 0.6 second, 300 °F (149 °C), and 80 PSI. This seal received two to three activations
with the sealer.
[0093] The bag was folded about 5.5 inches (about 14 cm) from (and parallel to) the bottom
seal of the bag that was just made. Holding the bag partially folded, with both ends
up, 69.5 grams of corn kernels were poured into the bag through its top. Next, a mixture
of 5 grams of partially hydrogenated soybean oil and 2 grams of powdered salt was
added to the bag. The top of the bag was sealed with one activation of the heat sealer
for 0.6 second at 300 °F (149 °C), and 80 PSI.
[0094] When cooked in a 1200 watt microwave, oven the containment pouch burst after approximately
19 to 35 seconds of exposure to microwave energy, the first popcorn kernel popped
at about 40 to 58 seconds, the total pop time was from 1 minute 57 seconds to 2 minutes
17 seconds, and the pop volume averaged 3007 ml.
[0095] Comparative Example - Three bags of a commercially available popcorn product (Orville
Redenbacher's Butter flavor) were popped. The first kernel popped at 46 seconds, the
pop time averaged 1 minute 40 seconds, and the pop volume averaged 3150 ml.
Example 2 (background of the invention)
[0096] Example 2 was a popcorn product incorporating a single cell containment pouch for
containment of trans-fat free oil and popcorn kernels. Four containment pouches were
made and tested using a similar procedure and the same materials as described in Example
1, except as noted.
[0097] Containment pouches, 5.0 inches x 5.5 inches (12.7 cm x 14 cm) were made by the same
procedure as in Example 1. 69.5 grams of corn kernels were poured into the pouch.
Next, 22.05 grams of liquid oil were added to the pouch; again, care was taken not
to contaminate the seal area with the oil. The fourth and final seal was made using
the same technique as previously. The seal was slit and the opposite side was glued.
[0098] The containment pouch was positioned and secured to a bag in the same manner as in
Example 1. The bag was folded about 5.5 inches (about 14 cm) from (and parallel to)
the bottom seal of the bag that was just made. Holding the bag partially folded, with
both ends up, 5 grams of partially hydrogenated soybean oil and 2.75 grams of powdered
salt were poured into the bag through its top. The bag was sealed as described above.
[0099] Two-week old bags were placed in a medium (1100 watt) wattage microwave oven. The
average pop time was 2 minutes 30 seconds, and the average pop volume was 3088 ml.
There was no off flavor, and there was no loss of crispiness of the popped corn.
[0100] The foregoing description, which has been disclosed by way of the above examples
and discussion, addresses embodiments of the present disclosure encompassing the principles
of the present invention. The embodiments may be changed, modified and/or implemented
using various types of arrangements. Those skilled in the art will readily recognize
various modifications and changes which may be made to the present invention without
strictly following the exemplary embodiments and applications illustrated and described
herein, and without departing from the scope of the present invention which is set
forth in the following claims.